< PreviousAchieve absolute control and‘Product Inspection Systems’consistency with the Vantage In-LineEffortless compliance with customer and legislative demands (including BRC, M&S and Tesco).Combination Checkweighing and Metal Detection SystemContact Stevens Group - Leaders in Weighing & Traceability Solutions- for a specification overview now: Stevens Group LtdGreenbank Technology Park, Challenge Way, Blackburn, Lancashire, BB1 5QBTel:+44 (0) 1254 685200 Email:info@stevensgroupltd.comFax:+44 (0) 1254 685202 Web:www.stevensgroupltd.com28-32:Layout 1 18/5/12 11:02 Page 3VISION, INSPECTION & DETECTIONwww.fdiforum.net31and affecting products’ profitability,metal detection is a often a quick andefficient process. Metal contamination israre, but can have a devastating effect ifit makes it through to sale. Often it isembedded within foods and so is notvisible to the naked eye. This means thatmetal detection is an essential element ofany processing system.What happens if you have a problemwith placing products automatically intopackaging? Vision systems can help bydetecting when something has goneamiss. If a product is malleable, such as ajuice box or carton, it can be quitecommon that an element will have beendamaged given its soft nature. Visionsystems can be placed in such a way as toavoid these situations. Being able to tellif a crate or tray does not look right interms of spacing or shape means alertscan be issued and machinery stops beforedefective products make it to the stage atwhich it will cause problems. This can be invaluable, as not only willit detect if the product looks damaged,but also if items are not aligned properly.This can help as incorrectly-synchedbottles, cans and packages can causeproblems such as becoming lodged inmachinery, bursting over electronics andmechanised parts or simplycontaminating other products throughbreakage or food seepage. Where glass ordelicate products are being used, it canalso prevent dangerous breakages, whichcan lead to further contamination.Label inspection can also beconfigured in many vision systems. Theway a product looks on a shelf shouldalways be uniform and recognisable, notonly in terms of alignment, but also incolour too. With alignment, a skewedlabel will not only look unprofessionaland awkward, but if the product isrepeatedly mis-labelled it could well32 Detection systems are essentialwhere seeing inside productswith the naked eye isimpossible, useful for freshproducts such as in the bakerysector.PHOTO: FORTRESS TECHNOLOGYMASTER MAGNETS LTDIncorporating Metal Detection LtdBurnt Meadow Road, North Moons Moat, Redditch, Worcestershire B98 9PATel: +44 (0)1527 65858 Email: info@mastermagnets.co.uk28-32:Layout 1 18/5/12 11:02 Page 428www.fdiforum.netVISION, INSPECTION & DETECTIONVeriSens®- Inspectionmade easyThree new ranges of VeriSens sensors from Baumeroffer simple operation & maximum performance forany visual inspection application. FAST, ACCURATE TEXT RECOGNITIONThe VeriSens® ID Series quickly and accurately identifiesmatrix & barcodes, including GS1, whilst the ID-110 also reads andverifies printed text (OCR/OCV). The ID series can recognisemultiple code, text and dot matrix text without time consumingfont training. Up to 32 features can be checked at the same time.RELIABLE CHECK & SORTCheck and Sort tasks for quality control purposes are particularlyeasy to solve with the VeriSens® CS Series. By providing 5 digitaloutputs, it can check components for various characteristics andsort them directly without external PLC requirements. In additionthe new FEXLoc® technology guarantees reliable 360° positiontracking of variable component positions.SIMPLIFY COMPLEX INSPECTIONThe VeriSens® XF Series offers the high performance of avision system with the ease of use of a vision sensor. The intuitiveand unified user interface enable validation of componentgeometries, part location or validation of correct labelling andpackaging.All new generation VeriSens® vision sensors are integrated intoindustrially robust IP67 metal housing and achieve high productionrates by performing up to 3000 evaluations per minute. Combinedwith the uniform, intuitive operating software and extremelysimple integration, the new VeriSens® series permit flexibleoperation during changing requirements and applications.Call us today on 01582 764334 and mention code VSFDI foran introductory 5% discount.Lambda Photometrics Lambda House Batford MillHarpenden Herts AL5 5BZ United KingdomTel: +44(0)1582 764334 F: +44(0) 1582 712084E: contact@lambdaphoto.co.uk W:www.lambdaphoto.co.ukcause many products to stick together, ruining what issome products’ only recognisable packaging. Similarly, if alabel cannot be fully read, legislation may be broken andtrouble could sprout from there while if a label does notdisplay all ingredients and a customer consumessomething harmful to allergies the manufacturer will be atfault. With colour, it has been proven people look torecognisable brands on the shop shelf. If a product comesout with a slightly different hue, the product may eithernot be spotted, or considered an imitation. While a shopmay refuse to stock it due to lack of uniformity. Brandidentity is important and any blemishes on colour qualitywill mean damage to your reputation.Vision systems, as well as inspection and detectionsoftware are your eyes where you can’t see. With suchtechnology at your disposal, there seems to be little excuseto fall foul of human error. Costly mistakes can be madewithout some form of detection and you can’t account forcontaminants entering your product if a line extendsacross a large area such as a factory. Vision systems couldwell insure you against unexpected expense and can keepyour flagship products safe and their reputationunblemished.Lock Inspection's INSIGHT rangeof metal detectors identify rejectand provide real time productand batch data to ensure fulltraceability crispsPHOTO: LOCK INSPECTION28-32:Layout 1 18/5/12 11:02 Page 5VISION, INSPECTION & DETECTIONwww.fdiforum.net33Case packingmade better withmachine visionThe Matrox Imaging authorised integratorhas developed a complete smart camera-based beverage inspection systemA beverage manufacturer wasexperiencing issues with casepacking orientation andcount errors,resulting incustomercomplaints andmachine downtimedue to jams.AcquireAutomationdeveloped acomplete inspectionsystem integrated toan existing casepacker to solvethese issues. Theintuitive Human MachineInterface and inspection system uses a Matrox Iris GT smartcamera for imaging and tool algorithm execution. The solution wasinstalled within the case packer to count and verify the orientationof 40- and 50-count cases of shrink-wrapped and non-shrinkwrapped juice boxes. The system has been able to detect boxflap/tab up, crushed boxes/extra boxes/rotated boxes (result incrushing), missing boxes, splices, and damaged and floating trays.The system automatically saves failed inspection images forsubsequent evaluation. The HMI provides log-in access control toprevent unauthorised personnel from altering the system, andincludes detailed product counters for data collection and trendestimation.The solution has received positive feedback from the customersince it has resolved their packing orientation and count errors.The vision system not only works to identify product issues, but italso helps to quickly identify a process issue and, often, the rootcause of the failure.Acquire Automation isa Matrox imagingauthorised integratorwho develops turn-keyvision system constructedwith the best componentsin the industry. Theintegrators enrolled inthis program havedelivered hundreds ofvision systems to a widerange of manufacturingfields and disciplines.A complete packaginginspection system is integratedwithin an existing case packerto accurately count and verifythe orientation of juice boxesThe operator interface shows the inspected image, andprovides inspection controls and pass / fail statistics.33:Layout 1 18/5/12 09:22 Page 134www.fdiforum.netCONTROL AND AUTOMATION SHOWCASENanotec launches AS5918 series IP65 stepper motors with a magnetic24V encoder and an optional brakeAlldrives & Controls is introducing new models AS5918-EMN24 and AS5918-EMN24B, expanding its product portfolio by addingIP-rated stepper motors with an integrated, magnetic 24V encoder and on the EMN24B model, an integrated brake.The entire IP protection class-rated AS motor line from Nanotec Germany, stands out thanks to high positioning reliability inharsh environments and compact design. The two new AS5918-EMN24 and AS5918-EMN24B models from the renowned steppermotor manufacturer distinguish themselves chiefly with their magnetic 24V encoder. The encoder was developed by Nanotec forintegration into IP-protected motors. Magnetic encoders are less sensitive to vibrations, dust, dirt and humidity. The option with a safety brake is used wherever vertical loads have to be kept in place even during a power failure or an emergencystop in order to prevent damage to persons or property. This applies to Z-axes and other safety-critical applications. Featuring a holding torque of 1.98 Nm, both motors are viable alternatives to servomotors with gearboxes in Torque Mode and Closed Loop at low speeds. This isbecause they are more compact and have greater energy efficiency - whether in mechanical engineering devices or other systems where operating in a harsh environment.Tel: 01543 271899 Email: john@alldrivesandcontrols.co.ukwww.alldrivesandcontrols.co.ukFlexibility breeds successGainsborough Engineering, located on the Corringham Road Industrial Estate in the Lincolnshire town, was foundedover 45 years ago.Primarily an engineering company that specialises in the manufacture of vertical form fill and seal machines, thisinnovative company also manufactures conveyors and rotary volumetric cup fillers. Gainsborough Engineering designs,manufactures, assembles, tests and installs all of its revolutionary machines. In-house, the company has design and detailfacilities as well as a comprehensive electronic software facility where it’s highly experienced staff write programmes forGainsborough and associated equipment.Due to Gainsborough Engineering being a privately owned company manufacturing its own equipment, it enables flexibility in order to satisfy its customers’needs. This has certainly proved to be a major advantage for many companies who require something a little different. Gainsborough have excellent relationshipswith other OEM’s, which has made the choosing of ancillary equipment relatively easy while guaranteeing a successful Installation. Adrian Shenton, Sales Director, says, “Our product range covers the entire packing arena from 0.5g up to 25 kilograms. We are active within many industries –food (both fresh and frozen), liquids, powders and solids, hardware, pharmaceutical, confectionery, electrical and the building industry.”For more information call 01427 617677, email sales@gains-eng.co.uk or visit www.gains-eng.co.uk.34:Layout 1 18/5/12 09:23 Page 1END OF LINE PACKAGINGwww.fdiforum.net35End of Line packaging protects notonly your products, but your reputationtoo, and innovations within the industrymean that cost reduction is always beingaddressed. Because everyone’s needs aredifferent, the solutions that could applyto your business are myriad. Take the task of sealing for example.Products that differ in shape or size canbe a problem for most automatedmachines which can only be set for onestandard measurement most of the time.There are new innovations which existthat can deal with non-standard shapesof boxes and packaging, and at a fastpace, meaning you lose no valuable timeand therefore are still saving money.The machines produced can deal withhigh volumes and loads and snackmanufacturers are taking advantage ofthis innovation. Use of multiple servos to track caseand head positions for exactsynchronisation and to maximisethroughput and reliability means thateven the most awkwardly-shapedpackages can be dealt with easily.Equally, packaging awkwardly-shapedor loose products is also difficult, butthere are solutions abounding all the timeto ensure time is not wasted. A recentdevelopment means netted citrus fruitscan be packed into trays crates andcartons in a fully-automated way for thefirst time ever. The machine, which can pack sixtynets of fruit per minute, replaces thecurrent labour intensive approach ofloading netted products into crates, trays36 Going to theend of the lineWhen it comes to packaging products for distribution, there are many options available, butwhich will save you money in the long run?The Genesis Cubepallet wrapper is ahigh-speed andaccurate solution towrapping large loadsfor transitPHOTO: AETNA35-39:Layout 1 18/5/12 11:09 Page 136www.fdiforum.netEND OF LINE PACKAGINGand cartons by hand via a rotary table. Not only is the rotarytable process costly due to high staffing requirements, bags offruit are often wasted when packers accidentally drop theproducts, or they are bruised when the handler loads them into atray resulting in costly penalties charged by retailers. Thischallenge prompted independent Food Production ConsultantTrefor Mason, who redesigns food manufacturing processes toachieve a leaner way of working, to approach companies todesign an automated solution which would eliminate waste andincrease line throughput. Trefor says, “Having worked with many fruit packers andsuppliers it is apparent that the packing of the netted fruits intotrays is an area which requires a complete overhaul.“My client is a fruit supplier to many leading supermarketchains and having assisted them in the redevelopment of theirfactory we began to look for an automated solution which wouldovercome the drawbacks of manual packing and ultimatelyeliminate product bruising, increase line throughput and re-deploy manual workers.”Simple steps mean easy tea adminPallet pools is something not every manufacturer may havelooked into, such a simple step, it can often save you incredibleamounts of time. Tetley has recently taken on a flexible palletpool, which will see all Tetley’s annual 200,000 palletmovements taking place on distinctive red pallets.In changing pallet pools, Tetley is benefiting from a reducedadministrative burden, with less complex invoicing and all palletcollections, repair and recirculation undertaken by their supplier.This outsourced service, known as the one-way-trip, enablesTetley to focus its supply chain team on more important issues.Terry Naylor, logistics manager at Tata Global Beverages, thecompany that owns the Tetley brand, says, “Pallet quality isvitally important; retailers are exceptionally stringent about whatthey will accept and the increase in automated warehousingmakes this even more critical. We had to be confident that thepallets we chose would deliver time and time again. Systems likePushers gently positionfruit from the parallelconveyors onto thelowering plates onPacepacker’s newpackaging solution toloose fruit productsPHOTO: PACEPACKER FLEXAPAC35-39:Layout 1 18/5/12 11:09 Page 2END OF LINE PACKAGINGwww.fdiforum.net37this take minimal investment and cansave vast amounts in lost time andtracking pallets that are uniform withevery other manufacturer can be a longprocess.Safety as well as protectionCorrugated is an area in which moreand more companies are investing in,particularly for protection. While the UKcorrugated packaging sector is at theforefront of innovation, it is said that itmust continue to invest in newtechnology if it is to remain competitive.That was the message from a recentEurope-wide industry conference held inAustria. More than 250 top packagingprofessionals from across Europeattended the prestigious EuropeanFederation of Corrugated BoardManufacturers Summit in Vienna,including Andy Barnetson, Director ofPackaging Affairs at the UK’sConfederation of Paper Industries.Mr Barnetson says, “I am pleased tosay the UK is leading the way ininnovation. The corrugated packagingsector in the UK is a pioneering force insustainable lightweight recyclable container boardfor shelf ready packaging and is investing heavilyin new equipment. The UK packaging industry ismore innovative than many other countries.“Multinational product companies like Proctor& Gamble want more from corrugated packagingsuch as value for money, guaranteed supply andinnovation. It is clear that if the Europeanindustry does not have innovation as one of itskey messages then we need to make it one.”This mention of guaranteed supply shows thesupport for the material in use for packaging.Corrugated cardboard offers a level of protectionnot seen in other materials. Its structure is suchthat it is easily stacked, folded and is hard tocrush. It also means retailers can use it directly asa shelf-ready display, a time saver as well assaving on material protecting it. One company who have run with the idea ofcorrugated as a prominent solution is DS SmithPackaging, who are at the forefront of the retailready packaging revolution.This has led to vast improvementsin efficiency at supermarkets -effectively the differencebetween spending thirtyminutes stacking items, andsimply pushing a box onto38 CDiWorldwide is a well-established designer and manufacturer of custom-built end-of-line packaging machineryTray Erectors lTray Loaders l Shrink Wrappers lIntegrated SystemsFor more information call 01502 515125 or visit www.cdiworldwide.comRobotic palletisers can beused to wrap in a moreefficient way than by handPHOTO: AETNA35-39:Layout 1 18/5/12 11:09 Page 338www.fdiforum.netEND OF LINE PACKAGINGa shelf. It wasn’t just at the on the shelfstage that savings were made. Retailready packaging is commonly strongenough to be used in all stages of thetransportation chain, and with carefuldesign and engineering can be incrediblystrong and rigid. Corrugated card itself isoften stronger than most other forms ofcontainers, and comes at a fraction of theprice. What’s more it is fully recyclableand can be recycled with almost 99%efficiency into new boxes, a key factor inthe supermarket’s goals to become carbonneutral.The final advantage would come intransport costs themselves, having astrong yield threshold, corrugated cardtransport containers can be stacked muchhigher upon each other, than older stylecontainers could. This eliminated wastedspace at the top of a lorry, which mighthave previously been left empty for fearof crushing goods. This in turn led tofewer lorries being necessary fortransportation and carbon footprintreduction. With all these advantages, it is almostsurprising then, to hear that many goodsare still sold outside of RRP. Manysupermarkets and retailers have come toexpect it as standard, and it will certainlylead to diminishing sales formanufacturers in the industry to fallbehind their peers. Ready for the shelf solutionsIn a similar way to corrugated, wineand spirit manufacturers are seeing moreand more innovations as packagingbecomes more intelligent. Ready for theshelf solutions are becoming morepopular, with products arriving atretailers requiring little or nomaintenance. One innovation recentlyfrom Smurfit Kappa is their new Bag-in-Box design for wine. The Pouch-Up solution is attractive tocustomers for its aesthetics, consumerconvenience and its weak carbonfootprint and comes in a variety of sizeswhich should please most retailers as itWWW.MARDENEDWARDS.COM INFO@MARDENEDWARDS.COM +44 (0)1202 861200Established in 1961, are specialists in the design, manufacture and supply of Food & Drink machinery to over 150 countries worldwide.Marden Edwards Limitedoverwrapping technologyReady for shelfpackaging maywell be thenorm in yearsto comePHOTO: SMUFIT KAPPAChanging something as simpleas your pallet pool colour canimprove your costs massively. PHOTO: LPR/TETLEYprovides a modicum of choice. Availablein formats 1,5L and 3L. Another boost isthat the totality of its surface can beprinted in high-quality, meaning brandrecognition in the store. The film usedon the tap Vitop compact ensures thepack contents remain untainted byoxygen ingress during dispense andextends the shelf life of the liquidfoodstuff after opening. Although glassand plastic bottles are the maincontainers used in the delivery of wine,perhaps these innovations could be seenas the norm in years to come.End of line packaging is important, notonly in terms of protection of valuablecommodities within food and drink, butalso in terms of aesthetics. With moreinformation needing to be displayed thesedays thanks to legislation changeregarding health benefits and nutritionalvalues, the packaging industry may wellhave to adapt in the future tocompensate.35-39:Layout 1 18/5/12 11:09 Page 4Great benefitsfromPlasfilmsPlasfilms, part of the Plastribution group, the UK’s number onepolymer distributor, are working hard to bring a true high speedfilms distribution model to UK printers and convertors, foodindustry packers and the labels market.Plasfilms represent a number of the world’s best filmmanufacturers for CPP, BOPP, PET and Heat Shrink Films. Theprimary focus is films, and great packaging films really help to sellproducts. KWH Plast, who exclusively manufacture CPP andbarrier films, are the first choice supplier for clear films that showand protect the product, are easy to open and offer barrier, anti-fog and peel properties.KWH Starpeel and Startec films for the industryPlasfilms can supply the KWH Starpeel and Startec brandsdirect to food industry packers, which provide many benefits...* Medium or high barrier laminates with high quality anti fog tomeet shelf life demands and provide excellent optical properties.This maintains excellent clarity and sealing behaviour and resultsin greater packaging security. These high-barrier laminates withEVOH ensure a long shelf life and product waste cost savings.* Starpeel is a self-peelable lidding film which has an excellentcombination of transparency and easy opening – even forrefrigerated products.* Startec is a film with fixed seal focused on higher speed on thefilling lines but still providing the same benefits of clarity, barrierand security.Bringing an expert films distribution model to the UKpackaging and labelling marketFor more details on these and many other products,such as CPP, BOPP, PET, Heat Shrink Films and SANZIPreclosable zippers, call 01480 308500 or visit www.plasfilms.co.uk.END OF LINE PACKAGINGwww.fdiforum.net39Adpak celebratessilver successAdpak have for 25 years been deliveringperfect packaging solutions to customerdistribution points and POSAdpak continue as leaders in thepackaging, shrink-wrapping machinery and materials sector. Tocomplement the existing range, Adpak also specialise in a rangeof innovative palletisation and pallet stretch-wrapping systems.Adpak succeeds by applying the latest technology andinnovations to unusual and sometimes difficult packagingproblems that arise due to the changing nature of today’sconsumer market. The range of machinery available is vast andvaries greatly in size, shape and level of automation. Thecompany offers simple standalone equipment through to turnkeysolutions with full project management from the experiencedtechnical department.Adpak Palletising market a range of innovative palletisationand pallet stretch wrapping systems, being based in a purposebuilt facility with six thousand square metres of production,warehouse, demonstration and office space. They offer bothrobotic and conventional systems, which can be customisedaccording to your specific applicationTheir palletising work goes from strength to strength, currentlysupporting over a hundred systems in the UK. Indeed, Adpakhave recently secured a substantial order with the UK’s largestwine distributor to automatically palletise cases of wine productsAdpak is a member of the influential Processing and PackagingMachinery Association and the company’s pioneeringinvolvement within the packaging industry has led to a long listof satisfied clients – large, medium and small – over 25 highlysuccessful years.Tel: 01282 601444 www.adpak.co.ukNo.1 FOR SHRINKWRAPPING& END OF LINE EQUIPMENT35-39:Layout 1 18/5/12 11:09 Page 5Next >